For someone only seeking basic speed control of the drives, I’ve prepared a step-by-step process on how to quickly setup and control any Yaskawa VFD over PROFIBUS using the Basic Data message package.

Step 1: Setup Your Hardware Configuration

1. Download the Yaskawa drives GSD file from Yaskawa’s web site from this download link. Note: All Yaskawa drive models can communicate over PROFIBUS using only this one GSD file.
2. Install the GSD files in the HW Config tool by going to Options and selecting Install GSD File…

   

3. In the dialog box that was just opened, click Browse…Then navigate to the location of the recently saved GSD file. Select YASK0ACF.gsd and then press Install.
4. Add the newly added Yaskawa VFD to your PROFIBUS network. Expand the right panel menu to find the Yaskawa drive in the following folder location: PROFIBUS DP -> Additional Field Devices -> Drives -> SI-P3 PROFIBUS-DP INTERFACE CARD. Drag this onto your PROFIBUS rail.

   

5. Assign drive a PROFIBUS address by double clicking the newly added drive. Note: This number will have to match the PROFIBUS address entered on the drives front keypad.

   

6. Finally, configure the packet of data exchanged over PROFIBUS. For many simple speed control applications, exchanging the basic data package is sufficient. More complicated applications may require extended data packets. In the right panel menu, drag basic data into the correct location in your project.

   

Step 2:  Handle the incoming information with your code

When using basic data, Yaskawa drives transmit data via 3 input and output words. The inputs words are Status, Speed, and Current. The three output words are Operation, Frequency, and Torque. When using more than one VFD in the project, I recommend creating a VFD function block similar to the one shown below – having the three input and output words as inputs and outputs to the function block. 

Now, let’s look closer at the 3 input words the drive sends over PROFIBUS.

First, the status word contains information related to the current operating Status of the drive. For simple applications, the most important bits are listed below along with an example code usage.

• Bit 0: Forward Running Feedback
• Bit 2: Reverse Running Feedback
• Bit 7: Drive Error Exists

The other two input words (Speed and Current) contain the measured speed and the measured current of the VFD. These variables are received as a percentage converted to engineering units – meaning 0-27648 raw input corresponds to 0-100% (0-60 Hz when considering speed). For example, a raw input of 13824 corresponds to 50%, meaning the drive is currently operating at 30hz. 

The output Operation word contains information related to the commanded status of the drive. For simple applications, the most important bits are listed below along with an example code usage.

• Bit 0: Motor command forward
• Bit 1: Motor command reverse
• Bit 9: Reset drive error

The other two output words sent to the drive are the commanded Frequency and Torque. Similar to input words, these need to be sent as a percentage proportional to the engineering units 0-27648 to 0-100%. For example, a 60 Hz command frequency or 100% and should be sent as 27648. A 30 Hz command frequency or 50% and should send a value of 13824 in the frequency word. 

Step 3: Configuring the drive parameters to accept commands over PROFIBUS

In order for the drive to correctly operate as commanded by the PLC, the following internal drive parameters need to be changed. This can be accomplished from the front of the drive, using the keypad and display.

After changing the drive’s communication parameters, power must be cycled in order for the changes to take effect.  

Once you’ve cycled power, you’re finished! Your drive should now receive commands from your PLC over PROFIBUS!

Learn more about DMC’s PLC Programming Services. 

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For this project, all programming was done using Yaskawa’s MotionWorks IEC Express. We were using a Yaskawa MP2300IEC Motion Controller with a few SGDV Sigma-5 Servo Amplifiers to control a set of servos. One of the axes controlled the X-position of a part with respect to our tooling. 

For the process, a part would be loaded and then moved into position. A sensor fed directly into the motion controller would then locate the leading edge of the part and very precise position moves would be used to properly locate the tool with respect to the leading edge for the tooling that needed to be done.

Initially, this worked great. While testing at relatively slow speeds, we were seeing excellent accuracy. However, as we wanted to speed up the through-time of the process, we wanted to make each move as quickly as possible, but we found that as we sped up the loading move, our accuracy became unacceptable. This was a concern we’d had while programming – that the accuracy of our in-software position latching would be limited by the scan rate of the PLC. Initially, as we were unsure of the final gearing ratios and required velocities on the servos, we made the decision to give it a try anyway.

Luckily, Yaskawa has made it very simple to make the switch to hardware-based position latching by providing inputs directly on their Sigma-5 Servo Amplifiers and allowing the amplifier itself to do the position latching. 

When the digital input is read high (or low, depending on how the user chooses to configure it), the amplifier reads the current position and saves the value to one of its internal parameters. This parameter can then be read directly from the MP2300 to extract the latched position. As the Sigma-5 amplifiers are orders of magnitude faster than the PLC, we can now get a much more accurate latch.

Furthermore, Yaskawa makes it simple for the user to implement, as there are already function blocks available to arm the latch and read the necessary parameters. Yaskawa provides an excellent application example (with code and manual) on their website that saved me a lot of time. 

Basically, it boils down to the following steps:

Step 1: Wire the sensor to the EXT1, EXT2, or EXT3 inputs on the amplifier’s CN-1 connector (Yaskawa actually provides latching inputs that can be individually configured as needed). To do this, you will need a CN-1 connector cable.

Step 2: From the Hardware Configuration tool embedded in MotionWorks, you will need to configure a few PN parameters. The reference manual for the servo amplifier you are using will direct you to the correct parameters.

In my case, to use EXT1 I needed to configure the following: PN820 = 2147483647, PN822 = -2147483648, and PN511.1 = 4 (this setting will be determined by your wiring of the latching input – NO or NC).

Step 3: Create a TRIGGER_REF.

In my code, I try to have an initialization POU that only runs on startup. For example, in the code below, I’ve initialized two axis and a TRIGGER_REF. In this case, I’m configuring my latch to use EXT1. If I were using EXT2, I would need to initialize my TRIGGER_REF to UINT#2.

Step 4: Now that you’ve configured your trigger and initialized it in your project, you can use it. The easiest way is to just drop in the MC_TouchProbe block provided in the PLCOpenPlus Toolbox. 

Using the high-speed encoder position latch is now simple. You simply provide an axis and a trigger reference and arm the TouchProbe block when you’re ready to watch for an input.

When the amplifier sees an edge (rising or falling, depending on your configuration), it stores the encoder position and sets a done output bit. Now all you need to do is read out the RecordedPosition. 

Learn more about DMC’s Yaskawa MotionWorks programming services.

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If you’re not familiar, Yaskawa’s new A1000 variable frequency drive maintains all the abilities of the F7 and G5, but adds even higher levels of performance and several new features – including permanent magnet motor control. The A1000 offers a wide range of power options (from 200-600 V, ¾-250 HP), several different control types, and a variety of communication options that make it an excellent option for both general purpose and high performance industrial applications.

The training course I participated in was designed to teach technicians and engineers the basics needed to incorporate an A1000 VFD into an application. Most of the time was spent doing hands-on programming of the drive for real-world applications such as fans, conveyors, mixers, and winders. By the end of three days I walked away feeling confident I could set a drive up for nearly any application. The capabilities of this drive are really impressive. And with the programming tools Yaskawa provides, setting one up, even for complicated applications, is simple.

Now I’m just looking forward for a chance to put one into action!

Learn more about DMC’s Yaskawa PLC programming services.

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